Water Mizer Brochure

WaterMizer Plate Processor Re-circulator - WWR30-AR or WWR30-AR/220 Installation & Operating Instructions NOTICE TO INSTALLER: DO NOT…..DISCARD THIS MANUAL AFTER INSTALLATION. THIS MANUAL CONTAINS IMPORTANT OPERATION, MAINTENANCE AND PRECAUTIONARY INFORMATION. PLEASE PRESENT THIS MANUAL TO USER/OPERATOR/OWNER AFTER INSTALLATION. IT IS STRONGLY ENCOURAGED THAT YOU READ THIS MANUAL BEFORE INSTALLATION TO COMPLETE THE BEST POSSIBLE INSTALLATION. INSTALLATION MUST CONFORM TO ALL LOCAL PLUMBING CODES. NOTICE TO USER/OPERATOR/OWNER: PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE FOR PARTS, MAINTENANCE OR TROUBLESHOOTING. IT IS STRONGLY RECOMMENDED THAT ALL PERSONNEL IN THE PREPRESS DEPARTMENT READ THE PRECAUTIONS, OPERATION AND MAINTENANCE SECTIONS OF THIS MANUAL. Overview The WaterMizer WWR30-AR Wash Water Re-circulator with fresh water replenishment is designed to re-circulate a given amount of wash water that is stored in the WaterMizer storage tank with the water in the plate processor wash tank. The recirculation of wash water will dramatically decrease the amount of water required by plate processing equipment conserving water and saving sewage costs. The user can set a timer to pump out a given amount of water. A float valve is installed in the WaterMizer tank and connected to a water supply. When the timer triggers the bellows pump water is pumped out of the tank and the float valve opens allowing fresh water to be automatically replenished. The bellows pump is adjustable in 30 minute increments and pumps up to 280 ml/min. The auto replenishment feature minimizes the concentration of the plate processing by-products while minimizing water usage. By utilizing a WaterMizer, water treatment to remove hardness and alkalinity from the water becomes much more practical since the volume of water to be treated is greatly reduced. The WWR30-AR is designed to decrease the amount of water used by a plate processor, a water source and drain is still required. The re-circulator output connects to the processor's wash water inlet. The wash water overflow to drain is then directed to the drain connection located on the back top corner of the storage tank. In some installations wash tank modifications might be necessary to enable the collection of the wash tank overflow. The WaterMizer WWR30-AR power connection is 115VAC, the WWR30-AR/220 is 220VAC. It can be plugged into a standard wall outlet or be connected to the power supply for the wash water solenoid (If it is 115VAC or 220 VAC). The wash water solenoid will only provide power to the WaterMizer when the processor is processing plates. Basic Installation 1. Empty wash tank and thoroughly clean tank, rollers, and rack. 2. Connect the quick-disconnect with the tubing (Processor Hook-up Line) to the re-circulator output. (Male barb to the right of the filter housing) 3. Connect the other end of the tubing to the processor wash tank inlet. (If processor is equipped with a water solenoid it is necessary to energize the solenoid when the WaterMizer is trying to pump water into the wash tank. If this is not practical simply bypass the wash solenoid and connect the tubing directly to the tank. Failure to open or bypass the solenoid will burn up the pump.) 4. Connect the quick disconnect with the “Wash Tank Overflow” large bore tubing to the re-circulator wash tank drain connection. 5. Connect the other end of the large bore tubing to the processor wash tank drain line. In some processors the wash tank overflow is connected to a manifold with tubing from an overflow tray located at the top of the wash tank. This overflow tray should be on the exit side crossover area of the processor. The existing drain line can be cut and the manifold side plugged. The overflow side should be connected to the WaterMizer drain connection or removed. If the line is removed then connect the tubing directly to the overflow tray fitting. IMPORTANT: Keep the drain line as short as possible and do not loop excess tubing. Try to maintain a gradual fall to the connection to allow for good drain flow. 6. Connect the 1/2" id reinforced vinyl tubing to the Fresh Water Inlet hose barb on the right side of the tank and clamp. Attach the other end of this tubing to the fresh water supply. 7. Connect the 3/8" id clear vinyl tubing to the outlet of the bellows pump and clamp. Connect the other end to a suitable drain. Timer Set-Up 8. Before connecting the power, remove clear cover on the timer box. The timer can be set to replenish continuously or as often as every other 30 minute time period. Ideally replenishment should only be done when the processor is making plates but can be 24 hours a day if required. Consider your usage pattern and determine your heaviest usage time frame. Replenish more in the heavier usage times and for some time after this period. The tank holds 30 gals of water or 113.4 liters. The bellows pump is capable of pumping 280 ml/min. In a single 30 minute period it would pump 8.4 liters. It would take 13.5 hours of bellows pump run time to completely replace the water in the tank. If you pulled out every other orange tab on the timer wheel the bellows pump would be on every other 30 minute period for the entire 24 hours providing 12 hours of run time. Pulling the orange tab out on the timer wheel turns on the bellows pump. If the orange tab is pushed in it turns off the pump. For example, pull two tabs out and push two tabs in would provide one hour of pump actuation and on hour of pump idle. In most cases we recommend starting with a replenishment cycle of every other 30 minutes. Basically pull out every other orange tab for the amount of time that you are running the processor. The timer motor is independent of the power switch that enables the re-circulator and bellows pumps. Operation 1. Make certain Quick Tank Drain Valve is closed and all connections have been completed. 2. Fill WaterMizer storage tank with water. (30 gals. or 113 liters for WWR30). Ideally, fill the WaterMizer with high-quality water. Water with high hardness or alkalinity is not good for plate processing, especially the new CTP medias. Many times printing plant pressrooms will have "RO" (reverse osmosis) systems that are used for preparation of fountain solution. This water is ideal for plate processing If this is unavailable Maratek has small water treatment systems for removing hardness and alkalinity from the tap water. 3. Check for leaks at all connections. 4. Connect WaterMizer power cord to 115VAC(or 220VAC) supply. Set time on timer by turning the dial clockwise until the "Time" arrow points to the current time. 5. Turn on power and check that water is pumping thru pump, and into filter housing. IMPORTANT: In some cases pump will have an air lock and water will not flow. Do not allow pump to run dry for more than a few seconds. The air lock can be purged by simply pressing the red button on the top of the filter housing while the pump is running. Hold the air-lock relief button down until water starts to flow into the flow meter. IMPORTANT: Never allow the pump to run dry for more than a few seconds. 6. Adjust flow rate to desired flow with the gray adjustment handle on the inlet of the filter housing. 7. When processing always turn re-circulator on a few moments before inserting plates. Water Changes The WaterMizer water supply should be changed and the tanks cleaned on a regular basis. This is determined on an individual basis because of variations in processing loads. Water changes are simple with the WaterMizer. A quick tank drain is located under the filter housing and allows for virtually complete draining of the storage tank. A 3/4” I.D. hose may be connected to the hose barb at the front bottom of the WaterMizer and placed in a floor drain. If the floor drain is not close by, the WaterMizer can be disconnected from the processor and rolled to a floor drain. If a floor drain is unavailable the spent water can be pumped into a sink drain by disconnecting the hose from the output of the WaterMizer. Connect the “Pumping To Drain Hose” to the output of the WaterMizer. Turn on power switch and use the recirculation pump to pump the spent water into the sink and down the drain. Filter Changes Filter life on the WaterMizer varies based on the chemistry, process and load. The filter should be changed when the pressure gauge (located between flowmeter and filter housing) reaches the red line (13psi). Maratek recommends that the filter be changed with Maratek approved filters. Maratek filter are designed for a minimum pressure drop and maximum life. Do not substitute stringwound for this application. 1. Turn power switch off and disconnect WaterMizer power supply. Lock casters so unit does not move with the lever on the side of the casters. 2. Press red button on top of filter housing to relieve pressure in filter housing. 3. Using filter housing wrench supplied turn sump in counter-clockwise direction to loosen. Carefully remove filter sump, water will be in sump with cartridge and could splash out if not removed carefully. 4. Pour water out into sink or drain and remove filter cartridge and discard. 5. Wash out filter sump with dishwashing detergent and warm water. Watch that the sump O-ring is not accidentally damaged or lost. 6. Replace filter cartridge. 9. Replace filter sump and hand tighten only Unit Features Filter Change Indicator Auto-Replenish Timer Main Power Switch Flow Rate Adjustment Valve Pump-Out Bellows Pump High Head Recirculation Pump Quick Tank Drain Fitting 3/4" Barb - Gravity drain to floor drain Locking Casters Processor Drain-To-WaterMizer Hook-Up Hose - 1" Fresh Water Inlet Output-to-processor Cam-Lock Quick Disconnect Pump-To-Drain Hose Processor Hook-Up Hose Housing Wrench